Big Ideas Lab podcast examines how machinists forge the future at LLNL

At Lawrence Livermore National Laboratory (LLNL), precision is more than a technical requirement — it's a craft, an art form and the heart of groundbreaking scientific discovery. In the latest episode of the Big Ideas Lab podcast, explore the fascinating world of machinists, the unsung heroes who transform raw materials into vital components for fusion research, national security and space exploration. Listen here on Apple or Spotify.

The episode takes listeners on a journey with machinists who blend traditional craftsmanship with cutting-edge technology. Drew Hash, an apprentice machinist whose unconventional path led him from the culinary world to mastering the intricate art of machining, shares his story of how precision became his passion. From his early days as a chef, where every subtle adjustment could mean the difference between a good dish and an exceptional one, Drew transitioned to knife-making — a craft that demands the same level of discipline and attention to detail. His journey evolved into the realm of machining, where the stakes are even higher and the tolerances even tighter.

“The possibilities are literally infinite as far as learning,” Hash says of a field that continuously challenges him to innovate and refine his skills.

Hash’s story is complemented by Dawn Hill, a senior machinist with years of experience at LLNL. Hill explains that the Lab’s approach to machining is unlike mass production — it’s about tailoring each component to meet rigorous specifications.

“You think of 3D printing or even additive manufacturing where you're starting with nothing and you're building material up,” Hill notes. “We're kind of the reverse of that. We start with a chunk of material, metal, plastic … and we're removing material to make a part out of that.”

Machinists begin with a solid piece of material and carefully remove what isn’t needed, a process that requires not only technical expertise but also a deep understanding of material properties. This engineering mindset ensures that every piece they craft, whether made of titanium, aluminum or specialized alloys, meets the exacting standards of the Lab’s high-stakes projects.

The podcast also highlights LLNL’s renowned Machinist Apprenticeship Program, a rigorous four-year course designed to train the next generation of precision experts. Through a blend of classroom instruction and hands-on experience in various machine shops, apprentices like Hash learn to master everything from precision milling to turning and grinding. This program not only teaches technical skills but also emphasizes critical thinking and problem-solving — qualities that are essential when working with materials that respond unpredictably to stress or heat.

Listeners will also gain a behind-the-scenes look at some of the Lab’s most treasured tools, like machines still prized for their unparalleled accuracy despite decades of use. Even as technology evolves, the foundational principles of machining remain constant — a reminder that while tools may change, the meticulous nature of the craft endures.

The episode further delves into the challenges that machinists face on a daily basis. Whether it’s adjusting for microscopic imperfections or managing the physical sensations — vibrations, sounds and even smells — that signal a machine’s performance, machinists must rely on both their intuition and their training. Hill and Hash share a vital truth: no algorithm can replace the seasoned judgment of a skilled human operator when it comes to advancing scientific discovery.

Tune in to the latest episode of the Big Ideas Lab podcast to hear these stories firsthand and learn how dedicated machinists at LLNL combine art, science and engineering to create parts that not only support national security but also pave the way for future scientific breakthroughs.

Listen here on Apple or Spotify.